High intensity gas fired infrared emitter

ABSTRACT

A high intensity gas-fired infrared emitter including a frame having a plurality of side walls, an open bottom, and an open top, a flame arrestor mounted inside the frame and including a bottom, a top surface having a recess, and a plurality of apertures extending from the bottom to the recessed top surface, and a cellular surface panel formed of a plurality of cells and mounted inside the recess of the flame arrestor such that the plurality of apertures of the flame arrestor form pathways which extend into the cellular surface panel.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication Ser. No. 62/306,214, filed on Mar. 10, 2016 and entitled“High Intensity Gas Fired Infrared Emitter”, the entire disclosure ofwhich is incorporated herein by reference.

FIELD OF THE INVENTION

The present disclosure is directed generally to high intensity gas-firedinfrared emitters, and more specifically, to high intensity gas-firedinfrared emitters including a flame arrestor and a cellular combustionmember to provide improved conversion efficiency.

BACKGROUND

Gas-fired radiant emitters are used, for example, for drying coating,controlling moisture profiles, processing industrial building equipment,curing, and other applications that require a large amount of heat to betransferred to a load in a very short amount of time. Typically, manyemitters are positioned side-by-side to extend across an industrialautomated machine or production line.

Unfortunately, a lot of time is required to maintain a large number ofemitters positioned side-by-side. Moreover, conventional gas-firedradiant emitters produce carbon monoxide (CO) emissions at 100 ppm andnitrogen oxide (NO_(x)) emissions at 30 ppm, both referenced to 3% O₂ indry flue products, which are undesirable. It is advantageous to improvethe overall conversion efficiency of gas-fired radiant emitters.

SUMMARY OF THE INVENTION

The present disclosure is directed generally to high intensity gas-firedinfrared emitters including a flame arrestor and a cellular combustionmember to provide improved conversion efficiency. The disclosedembodiments provide advantages over conventional emitters by making thedevice less prone to instances of backfire during operation.Additionally, the disclosed embodiments minimize energy loss throughcomponents of the emitter near the external surface which transfersheat. The combination of a flame arrestor and cellular surface panelallows for a high surface area with minimal losses, resulting inimproved conversion efficiency.

Generally, in one aspect, a high intensity gas-fired infrared emitter isprovided. The high intensity gas-fired infrared emitter includes (i) aframe having a plurality of side walls, an open bottom, and an open top;(ii) a flame arrestor mounted inside the frame and including a bottom, atop surface having a recess, and a plurality of apertures extending fromthe bottom to the recessed top surface; and (iii) a cellular surfacepanel formed of a plurality of cells and mounted inside the recess ofthe flame arrestor such that the plurality of apertures of the flamearrestor form pathways which extend into the cellular surface panel.

According to an embodiment, each of the plurality of cells of thecellular surface panel comprises a geometry to form a restricted pathfor products of combustion.

According to an embodiment, the cellular surface panel comprises atleast two consecutively connected solid porous bodies.

According to an embodiment, at least two consecutively connected solidporous bodies have different sizes.

According to an embodiment, the emitter further includes a body mountedwithin the frame and a resilient element configured to retain the flamearrestor, the cellular surface panel and the body within the frame.

According to an embodiment, the body supports a deflector platepositioned dimensionally offset relative to the body.

According to an embodiment, an offset is arranged between the flamearrestor and the body mounted within the frame to increase a volume of achamber formed therein.

According to an embodiment, the flame arrestor is made of a lightweightceramic fiber material composed principally of aluminum oxide andsilicon dioxide.

According to an embodiment, the emitter further includes a fire checkassembly coupled to the body to stop gas flow to the cellular surfacepanel in a failure event.

Generally, in another aspect, a high intensity gas-fired infraredemitter is provided. The high intensity gas-fired infrared emitterincludes (i) a frame having at least one side wall, an open bottom, andan open top; (ii) a flame arrestor mounted inside the frame andincluding a bottom, a top surface having a recess, and a plurality ofapertures extending from the bottom to the recessed top surface; (iii) acellular surface panel mounted inside the recess of the flame arrestorsuch that the plurality of apertures of the flame arrestor form pathwayswhich extend into the cellular surface panel; and (iv) a fire checkassembly coupled with the emitter. The assembly includes a solder jointpositioned proximate a gas outlet, and a plunger rod fixed to the solderjoint and in a compressed state via a resilient member. The solder jointis configured to break when exposed to a flame causing the plunger rodto be displaced to close a gas inlet.

According to an embodiment, the resilient member is a spring urging theplunger rod towards the gas inlet.

According to an embodiment, the cellular surface panel comprises atleast two consecutively connected solid porous bodies.

According to an embodiment, the flame arrestor is made of a lightweightceramic fiber material composed principally of aluminum oxide andsilicon dioxide.

According to an embodiment, the cellular surface panel is formed fromsilicon carbide (Si—SiC).

Generally, in a further aspect, a method of operating a high intensitygas-fired infrared emitter is provided. The emitter includes a frame, aflame arrestor mounted inside the frame, and a cellular surface panelmounted inside the flame arrestor. The method of operating includes thesteps of (i) introducing a combustible mixture into the high intensitygas-fired infrared emitter through an inlet manifold; (ii) dispersingthe combustible mixture into a cavity; (iii) forcing, by a deflectorplate, the combustible mixture to fill a chamber, (iv) forming apressure tight seal within the chamber; (v) passing the combustiblemixture through apertures within the flame arrestor to maintain a lowair-gas temperature prior to combustion; and (vi) igniting the mixtureto heat cells of the cellular surface panel.

According to an embodiment, the chamber is formed by at least onegasket, the flame arrestor, a cast iron body, the frame, and at leastone resilient member.

It should be appreciated that all combinations of the foregoing conceptsand additional concepts discussed in greater detail below (provided suchconcepts are not mutually inconsistent) are contemplated as being partof the inventive subject matter disclosed herein. In particular, allcombinations of claimed subject matter appearing at the end of thisdisclosure are contemplated as being part of the inventive subjectmatter disclosed herein. It should also be appreciated that terminologyexplicitly employed herein that also may appear in any disclosureincorporated by reference should be accorded a meaning most consistentwith the particular concepts disclosed herein.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing will be apparent from the following more particulardescription of example embodiments of the present disclosure, asillustrated in the accompanying drawings in which like referencecharacters refer to the same parts throughout the different views. Thedrawings are not necessarily to scale, emphasis instead being placedupon illustrating embodiments of the present disclosure.

FIG. 1 is a schematic cross-sectional view of a high intensity gas-firedinfrared emitter assembly, according to an embodiment of the presentdisclosure.

FIG. 2 is a schematic perspective view of a flame arrestor, according toan embodiment of the present disclosure.

FIG. 3 is a schematic view of a cellular surface panel, according to anembodiment of the present disclosure.

FIG. 4 is a schematic top view of a cast iron body, according to anembodiment of the present disclosure.

FIG. 5 is a schematic cross-sectional view of a fire check assembly,according to an embodiment of the present disclosure.

DETAILED DESCRIPTION OF EMBODIMENTS

A description of example embodiments of the invention follows. Althoughthe gas-fired infrared emitter assembly shown in the figures is shown inan upward orientation, the gas-fired infrared emitter is typicallyoperated in the downward orientation. Thus, the description of theassembly shown in the figures is not intended to be limited to aparticular orientation. The terms “top” and “bottom” as used hereindescribe elements of the assembly based on the upward orientation of theassembly shown in the figures. In other words, for example, the “openbottom side 4A” also represents “an open top side” when the assembly isrotated 180 degrees in use.

Referring to FIG. 1, a high intensity gas-fired infrared emitterassembly is shown schematically in a cross-sectional view according toan example embodiment of the present disclosure. A metallic housing isformed from a high temperature metal, such as, stainless steel. The highintensity gas-fired infrared emitter broadly includes a frame 1, a flamearrestor 9, and a cellular surface panel 10. In the embodiment shown inFIG. 1, the frame 1 comprises four vertical side walls 2, fourhorizontal edges 3 formed as a 90-degree continuation of each of theside walls 2, an open bottom side 4A, a substantially open top side 4Bdefined by the horizontal edges 3 and extensions 7, and four tabs 2A(two on each of the side walls 2) that contain slots 5. The flamearrestor 9 is mounted inside the frame 1 and includes a bottom, a topsurface having a recess, and apertures 44 extending from the bottom tothe recessed top surface. Cellular surface panel 10 is formed fromsilicon carbide (Si—SiC) and located within the confines of the flamearrestor 9.

To retain the cellular surface panel in place within the flame arrestor9, extensions 7 are included either integrally or otherwise within frame1. Extensions 7 extend from horizontal edges 3 in a direction away fromside walls 2. Extensions 7 can be made of any suitable metal, forexample, stainless steel. In an example embodiment, two extensions 7 arearranged on each of the longer sides of a rectangular frame 1.Additional or fewer extensions are contemplated. Any suitable sizes andshapes of extensions are contemplated. In an example embodiment, thehorizontal edges 3 include indentations such that the non-indentedportions retain the cellular surface panel in place within the flamearrestor 9. The slots 5 within the frame 1 are arranged to receiveresilient elements 6 on each side of the emitter. Resilient elements 6can be springs or any suitable alternative.

In an example embodiment, metallic components are formed inside each ofthe four corners of the frame 1. Such metallic components can be formedfrom a high temperature metal, such as, stainless steel, or any suitablealternative. The metallic corner components can be sized such that atleast 0.5 inches of metallic material, for example, extends in lengthand width directions, normal to the open horizontal face 4B. The cornercomponents can be fixed into position mechanically via a weld or anysuitable alternative along with additional compression force produced byresilient elements 6.

A rectangular gasket 8 is arranged inside the outer edge of frame 1 andwithin the boundary of the horizontal edges 3. The rectangular gasket 8can be made from high temperature ceramic paper or any suitablealternative. Coincident to the bottom side of paper gasket 8 is a flamearrestor 9, formed of high temperature ceramic fiber insulation or anysuitable alternative.

Referring to FIG. 2, a perspective schematic view of the flame arrestor9 is shown according to an example embodiment of the present disclosure.The flame arrestor 9 includes four side walls 40 that fit dimensionallyinside metallic frame 1. The side walls 40 can be integral or separatelyformed. In an example embodiment, each of the four side walls 40 isdefined by a wall thickness 41 of approximately 0.33 inches. Wallthickness 41 may define the shape of recess 42. Recess 42 extendsvertically downward to a point approximately forty percent of the totalheight of side walls 40 of the flame arrestor 9. Apertures 44 are formedfrom the bottom 43 through the top plane of recess 42 within theremaining sixty percent of the total height of side walls 40. In anexample embodiment, apertures 44 are approximately 0.04-0.06 inches indiameter and formed by drilling. However, any suitable method of formingapertures 44 is contemplated. In an example embodiment, the aperturesare arranged in a regular pattern. In an example embodiment, theapertures are arranged in an irregular pattern. The center-to-centerdistance between apertures 44 may be in the range of 0.15-0.3 inches,for example, and the density of the apertures 44 may be spread evenlyacross the plane of recess 42 to provide a total number of apertures inthe range of 600-800. However, additional or fewer apertures arecontemplated and the apertures need not be spread evenly across theplane of recess 42. The apertures 44 are arranged such that theapertures communicate with (i.e., form pathways which extend into) thecellular geometry of cellular surface panel 10 (shown in FIG. 1).

The flame arrestor 9 may be formed of a lightweight ceramic fibermaterial suitable for 3000 F and composed principally of aluminum oxide(Al₂O₃) and silicon dioxide (SiO₂). In an example embodiment, thesuitable material is composed of approximately 78 percent aluminum oxide(Al₂O₃) and/or 22 percent silicon dioxide (SiO₂) and/or a density of 25lb/ft³. The flame arrestor 9 also may exhibit continuous use up to 2950degrees Fahrenheit (or 3000 degrees Fahrenheit), thermal conductivity of1.25 Btu/(hr)(ft²)(° F./in), and 2.3 percent shrinkage at 2500 degreesFahrenheit. The high temperature range, high compressive strength, andminimal shrinkage allow the material to be processed with 400-800 holes,for example, without any surface cracking ensuring long emitter life.The insulation properties of the flame arrestor 9 effectively hold anair/gas mixture temperature on the bottom side of the flame arrestor 9(where an air/gas mixture enters the emitter) approximately 2300 degreesFahrenheit lower than a main combustion zone on the opposite side. Theflame arrestor 9 effectively insulates the frame 1 from the cellularsurface panel 10, thus minimizing losses and increasing conversionefficiency of the emitter.

The cellular surface panel 10 may have a profile that substantiallycorresponds in shape and size to the flame arrestor recess 42 and to thetop opening 4B of the frame 1. FIG. 3 shows a schematic view of thecellular surface panel 10 including an inner surface 45, side walls 46,and an external surface 47, opposite the inner surface 45. The cellularsurface panel 10 may be made of Si—SiC, which provides a high thermalconductivity, emissivity, shock resistance, and lower coefficient ofthermal expansion required to retain overall life of the emitter as itis subjected to extremely high thermomechanical loading. Any suitablealternative or combination of alternatives which provide(s)substantially similar characteristics is contemplated. Viewing thecellular surface panel in detail, cell 48 can be embodied as a truncatedcube or truncated hexahedron having about fourteen regular faces,thirty-six edges, and twenty-four vertices. Cell 48, and allconsecutively connected cells, may have diameters of differing sizesranging from 0.05-0.15 inches, for example, extruded through each of thefaces, increasing viewpoint surface area exposure through the externalsurface 47. The increased surface area created by the consecutivelyconnected and layered cells (truncated cubes) provides over five timesthe amount of surface area than the surface area of the external surface47.

Referring back to FIG. 1, a ceramic paper gasket 8A that is of similarshape and size of the ceramic paper gasket 8 is arranged coincident tothe underside of the flame arrestor 9. On the bottom side of the ceramicpaper gasket 8A may be rectangular gasket 11 of graphite composition,sized to correspond with the ceramic paper gasket 8A. A cast iron body12 may be positioned to rest against the graphite gasket 11 inside theconfines of the frame 1. The general convex envelope of the cast ironbody 12 and the offset distance created by the ceramic paper gaskets 8Aand 11 forms chamber 13 between cast iron body 12 and the flame arrestor9.

Referring to FIG. 4, a schematic top view of a cast iron body 12 isshown including pegs 49 positioned within the cast iron body 12. Pegs 49extend vertically to support the deflector plate 15 (shown in FIG. 1).The pegs 49 may be positioned such that the total amount on each side ofaxis 50 is equal. However, the number of pegs shown in FIG. 4 is onlyillustrative and additional or fewer pegs are contemplated. Thedeflector plate 15 may be formed from alloy or mild steel and caninclude four side walls that are offset dimensionally relative to theinside of the inner side walls 52 of the cast iron body 12. Dimensionaloffset 16 (shown in FIG. 1) between the deflector plate 15 and the innerside walls 52 (shown in FIG. 4) of the cast iron body 12 may be equalaround all four sides. Two pegs 51 can be arranged on each side of axis50 and can include female threads that communicate with openings in thedeflector plate 15. Screws can be included to retain the deflector plate15 in place within the cast iron body 12. Vertical support pegs 49 and acasting inlet manifold 17 (shown in FIG. 1) form a cavity 19 underneaththe deflector plate 15, which communicates with the chamber 13 throughthe offset gap 16 around all sides of the casting body 12. Cast ironbody 12 may include female threads at an inlet manifold 17 to accept afire check assembly 18 in an example embodiment.

FIG. 5 illustrates a schematic cross-sectional view of a fire checkassembly 18. The fire check assembly can include a short pipe nipple 53,a union 54, a pipe nipple 55, an insert 56, a frame 61, a plunger 62,and a resilient element 67. The resilient element 67 can be a spring orany suitable alternative. The short iron pipe nipple 53 communicateswith the union 54, and the iron pipe nipple 55 maintains a threadedconnection relationship with the union 54. The insert 56 may have anouter diameter that allows it to be press fitted into position insidethe iron pipe nipple 55, flush with a bottom face 57. The insert 56 mayinclude a bore 58, a counter-bore 59, and two slots 60 to accept bothsides 61A of the frame 61. The counter-bore 59 may be dimensioned suchthat it accepts plunger 62 if the two surfaces have a coincidentrelationship. Frame 61 may be formed of mild steel strip ofapproximately ⅛ inches thickness and 0.2 inches width, for example. Two90-degree bends form sides 61A, which correspond to the innerdiameter/length of the pipe run, which includes the short nipple 53,union 54, and pipe nipple 55. Cross members 64 and 66 may be positionedto support sides 61A, which may be fixed in position by mechanical weldor any suitable alternative. Each frame cross member includes a holedrilled concentric to bore 58 to communicate/guide plunger rod 65.Plunger rod 65 is fixed in place at solder joint 63. Resilient element67 is compressed against cross member 66. Resilient element 67 may bedimensioned such that its inner diameter corresponds with the outerdiameter of plunger rod 65 (allowing ease of movement), and has a lengthsuch that sufficient compression force remains present with plunger 62in a coincident position with counter-bore 59. The fire check assembly18 may be dimensioned such that the top of the frame 61 may be insertedinside the inlet casting manifold 17 of the emitter with, for example,approximately ⅓ inches clearance to the bottom side of the deflectorplate 15.

With reference to FIGS. 1-5, operation of the high intensity gas-firedinfrared emitter is explained as follows. A pre-mixed air/gas (e.g.,natural gas or propane) mixture can be introduced into fire checkassembly 18 in an air-to-gas ratio of, for example, approximately 10:1for natural gas (25:1 for propane) sufficient to, when ignited, produceflames and products of combustion. The flame arrestor 9 allows for areduced amount of excess air compared to prior technologies as excessair is not required for cooling of the emitter. A reduction in flow patharea is encountered by the air-gas mixture upon entering assembly 18,caused by insert 56 as well as frame 61 and plunger 62. The reduction inflow path area may be sufficient to limit the overall energy input tothe emitter (based on its maximum operating conditions), while at thesame time providing enough back pressure to allow any premix manifold todistribute the proper mixture equally to pluralities of emitters whenpositioned side-by-side to extend cross directionally.

Once the air-gas mixture exits the fire check assembly 18, the air-gasmixture is introduced into the infrared emitter through the castinginlet manifold 17 where it expands into the annular casting manifoldbefore dispersing into the cavity 19, formed from the general convexenvelope of the cast iron body 12. Once the air/gas mixture reaches thecavity 19, it encounters the deflector plate 15, which forces theair-gas mixture to fill the chamber 13 through the offset gap 16 (aroundall sides of the casting body 12), ensuring equal distribution anduniform emitter surface temperature profile.

The ceramic paper gasket 8A, graphite gasket 11, flame arrestor 9,casting body 12, frame 1, and resilient elements 6 not only allow theformation of chamber 13, but can also create a pressure tight seal. Thegasket combination 8A and 11 can create an increased offset between theflame arrestor 9 and the casting body 12, increasing the volume ofchamber 13 and dwell time of the air/gas mixture, further improvingdistribution effectiveness. The casting body 12, frame 1, and resilientelements 6 may be configured such that when in the assembled position,resilient elements 6 exert a homogeneous compressive force on thecasting body 12, which compresses gaskets 8A and 11 and the flamearrestor 9 against the horizontal edges 3 of the frame 1. Thecomposition of gasket 11 is such that the gasket spreads when compressedto fill any small voids that may be present between the casting body 12,frame 1, and flame arrestor 9. Additional sealing characteristics areachieved as the temperature of the graphite gasket 11 is increasedbeyond room temperature.

Once the reactants have reached the chamber 13, the mixture is forced topass through apertures 44 in the flame arrestor 9. In an exampleembodiment, apertures 44 are annular nozzles. The flow path traveldistance through each aperture in the flame arrestor 9 is such thatthere is enough material to insulate the air-gas mixture in the chamber13 from the combustion zone temperatures on the recess 42, maintaining alow air-gas premix temperature inside of the emitter (prior tocombustion), which is vital in reducing the occurrence of backfireduring normal operation of the emitter. The flame arrestor 9 alsoinsulates the metallic vertical side walls 2 of the frame 1 from thecellular surface panel 10. This effect minimizes energy loss throughparts of the emitter near the external surface 4B (the surface of theemitter that is meant to transfer heat). The material composition of theflame arrestor 9 can both ensure proper function through the insulationof the chamber 13 and minimize losses through the frame 1.

As the gas mixture enters the inlet of each aperture 44, the fluidvelocity increases, creating well defined fluid streams that extend intothe interconnected truncated cubes of the cellular surface panel 10. Anexternal ignition source may ignite the mixture and each of theapertures 44 can form very well defined flames that reach the top of thesurface 47 of the cellular surface panel (shown in FIG. 3). As theindividual flames heat the portion of the cells into which they extend,the reaction also releases products of combustion that circulate withinthe cellular structure prior to reaching the external surface 47. Thecomplex geometry of the cellular surface panel 10 forms a restrictedpath for the products of combustion, which, through transmission,transfer heat to the steady stream of reactants that continue to flowthrough the emitter body. The combustion methodology forces all flamesto dissipate, moving the combustion zone into the lower half of thecellular surface panel 10, concurrently. The stabilization of combustionwithin the bottom half of the cellular surface panel permits an ongoinginternal recuperation of heat and forms a homogeneous temperature fieldacross the surface of the infrared emitter, referred to herein as“cellular combustion.” Cellular combustion generates a very largetemperature difference in the products of combustion when measured atthe initial point of generation and at the point of exiting the externalsurface 47, increasing overall emitter conversion efficiency andcreating a peak energy wavelength that extends well into the shortwavelength spectrum. The peak energy wavelength ranges between 780 nm to1 mm. The combination of the disclosed flame arrestor and cellularsurface panel provides a high surface area with minimal losses,resulting in a very high conversion efficiency. Further, nitrogen oxide(NOx) emissions are less than 15 ppm at ten percent excess air atnominal firing rates and carbon monoxide (CO) emissions are typically atless than 100 ppm at ten percent excess air at nominal firing rates.Moreover, in installations using multiple emitters, significantly feweremitters are required due to the emitters' efficiency, thus decreasingthe time required for routine maintenance.

In an event that the emitter is operated outside the specified operatingrange and/or in an event or string of events that leads to failure(e.g., backfire into the chamber 13), solder joint 63 of the frame 61and the plunger rod 65 are positioned to cause quick failure of thejoint 63. Failure of the joint 63 releases the compression force causedby resilient element 67 resting in a compressed position against crossmember 66. Movement of resilient element 67 from a compressed state toan uncompressed state releases the compression force, moving plunger 62into a coincident position with counter-bore 59. The length of resilientelement 67 is such that the opposite side of resilient element 67remains in contact with cross member 66 causing enough of a compressionforce on plunger 62 to shut off the air/gas flow into the emitter.

While this invention has been particularly shown and described withreferences to example embodiments thereof, it will be understood bythose skilled in the art that various changes in form and details may bemade therein without departing from the scope of the inventionencompassed by the appended claims. For example, the cells 48 of thecellular surface panel 10 can be formed of any particular solid porousbody geometry. The cellular surface panel 10 can be formed of any numberof consecutively connected solid porous body geometries, can have anynumber of layers, and can be held in place using additional structuralsupport extending from horizontal edges 3 of the frame 1. The flamearrestor 9 can have a recess 42 of any depth and wall thickness toaccommodate the dimensional boundaries that define the cellular surfacepanel 10, can have any number of apertures, not necessarily round, inany pattern, and the apertures may contain larger recessed holes forincreased retention aperture surface area.

While several inventive embodiments have been described and illustratedherein, those of ordinary skill in the art will readily envision avariety of other means and/or structures for performing the functionand/or obtaining the results and/or one or more of the advantagesdescribed herein, and each of such variations and/or modifications isdeemed to be within the scope of the inventive embodiments describedherein. More generally, those skilled in the art will readily appreciatethat all parameters, dimensions, materials, and configurations describedherein are meant to be exemplary and that the actual parameters,dimensions, materials, and/or configurations will depend upon thespecific application or applications for which the inventive teachingsis/are used. Those skilled in the art will recognize, or be able toascertain using no more than routine experimentation, many equivalentsto the specific inventive embodiments described herein. It is,therefore, to be understood that the foregoing embodiments are presentedby way of example only and that, within the scope of the appended claimsand equivalents thereto, inventive embodiments may be practicedotherwise than as specifically described and claimed. Inventiveembodiments of the present disclosure are directed to each individualfeature, system, article, material, and/or method described herein. Inaddition, any combination of two or more such features, systems,articles, materials, and/or methods, if such features, systems,articles, materials, and/or methods are not mutually inconsistent, isincluded within the inventive scope of the present disclosure.

What is claimed is:
 1. A high intensity gas-fired infrared emitter, comprising: a frame having a plurality of side walls, an open bottom, and an open top; a flame arrestor mounted inside the frame and including a bottom, a top surface having a recess, and a plurality of apertures extending from the bottom to the recessed top surface; and a cellular surface panel formed of a plurality of cells and mounted inside the recess of the flame arrestor such that the plurality of apertures of the flame arrestor form pathways which extend into the cellular surface panel.
 2. The high intensity gas-fired infrared emitter of claim 1, wherein each of the plurality of cells of the cellular surface panel comprises a geometry to form a restricted path for products of combustion.
 3. The high intensity gas-fired infrared emitter of claim 1, wherein the cellular surface panel comprises at least two consecutively connected solid porous bodies.
 4. The high intensity gas-fired infrared emitter of claim 3, wherein the at least two consecutively connected solid porous bodies have different sizes.
 5. The high intensity gas-fired infrared emitter of claim 1, further comprising a body mounted within the frame and a resilient element configured to retain the flame arrestor, the cellular surface panel and the body within the frame.
 6. The high intensity gas-fired infrared emitter of claim 5, wherein the body supports a deflector plate positioned dimensionally offset relative to the body.
 7. The high intensity gas-fired infrared emitter of claim 5, wherein an offset is arranged between the flame arrestor and the body mounted within the frame to increase a volume of a chamber formed therein.
 8. The high intensity gas-fired infrared emitter of claim 1, wherein the flame arrestor is made of a lightweight ceramic fiber material composed principally of aluminum oxide and silicon dioxide.
 9. The high intensity gas-fired infrared emitter of claim 1, further comprising a fire check assembly coupled to the body to stop gas flow to the cellular surface panel in a failure event.
 10. A high intensity gas-fired infrared emitter, comprising: a frame having at least one side wall, an open bottom, and an open top; a flame arrestor mounted inside the frame and including a bottom, a top surface having a recess, and a plurality of apertures extending from the bottom to the recessed top surface; a cellular surface panel mounted inside the recess of the flame arrestor such that the plurality of apertures of the flame arrestor form pathways which extend into the cellular surface panel; and a fire check assembly coupled with the emitter, the assembly further comprising: a solder joint positioned proximate a gas outlet; and a plunger rod fixed to the solder joint and in a compressed state via a resilient member; wherein the solder joint is configured to break when exposed to a flame causing the plunger rod to be displaced to close a gas inlet.
 11. The high intensity gas-fired infrared emitter of claim 10, wherein the resilient member is a spring urging the plunger rod towards the gas inlet.
 12. The high intensity gas-fired infrared emitter of claim 10, wherein the cellular surface panel comprises at least two consecutively connected solid porous bodies.
 13. The high intensity gas-fired infrared emitter of claim 10, wherein the flame arrestor is made of a lightweight ceramic fiber material composed principally of aluminum oxide and silicon dioxide.
 14. The high intensity gas-fired infrared emitter of claim 10, wherein the cellular surface panel is formed from silicon carbide (Si—SiC).
 15. A method of operating a high intensity gas-fired infrared emitter, the emitter comprising a frame, a flame arrestor mounted inside the frame, and a cellular surface panel mounted inside the flame arrestor, the method comprising the steps of: introducing a combustible mixture into the high intensity gas-fired infrared emitter through an inlet manifold; dispersing the combustible mixture into a cavity; forcing, by a deflector plate, the combustible mixture to fill a chamber; forming a pressure tight seal within the chamber; passing the combustible mixture through apertures within the flame arrestor to maintain a low air-gas temperature prior to combustion; and igniting the mixture to heat cells of the cellular surface panel.
 16. The method of claim 15, wherein the chamber is formed by at least one gasket, the flame arrestor, a cast iron body, the frame, and at least one resilient member. 